NZ248371A

NZ248371A - Conductor connector housing: contact insertion bore

Info

Publication number: NZ248371A
Application number: NZ248371A
Authority: NZ
Inventors: Daines M Self; Richard D Hutchinson; Michael P Trull
Original assignee: Whitaker Corp
Priority date: 1992-09-29
Filing date: 1993-08-10
Publication date: 1995-12-21
Also published as: BR9303900A; US5425661A; FI934190A; CN1038168C; KR940008163A; DE69314757D1; AU666962B2; AU4487593A; CN1089398A; CA2104257A1; JP3398432B2; EP0605083A1; DE69314757T2; ES2108829T3; KR100293603B1; FI934190A0; MX9305900A; JPH06243921A; EP0605083B1

Description

<div class="application article clearfix" id="description"> 24 8 3 7 Priority Date(s):. Complete Specification Filed: Class: (6) Publication Date:. 2 t DEC. 1995 P.O. Journal No: J.PUl:. ■rv-$vP}' " ' „• v'\ : «• yiG-fe;-' "IV ' rw.- . NZ P'-Trv.T O-HCE 1 0 AUG 1993 RECEIVED v. . VfPk v.'r.. NEW ZEALAND PATENTS ACT, 1953 COMPLETE SPECIFICATION ELECTRICAL CONNECTOR HOUSING WITH IMPROVED CONTACT INSERTION >i/We, THE WHITAKER CORPORATION, a corporation organized and existing under the laws of Delaware, United States of America, of Suite 450, 4550 New Linden Hill Road, Wilmington, Delaware, 19808, United States of America hereby declare the invention for which i"/we pray that a patent may be granted tojn€7us, and the method by which it is to be performed, to be particularly described in and by the following statement:- - 1 - (followed by page la) 24 8 3 7 l ELECTRICAL CONNECTOR HOUSING WITH IMPROVED CONTACT INSERTION This invention relates to an electrical connector housing of molded plastic material having a contact 5 receiving bore facilitating contact insertion. A type of electrical connector widely used in interconnecting electrical and electronic devices employs a thermoplastic material sufficiently resilient to incorporate in one piece bores or cavities to receive 10 contacts and hinged elements to facilitate latching and fastening of connector halves together. Such connectors are used in high volume and accordingly, are made in multiple cavity molds with mold cycle times as short as possible, consistent with the material employed and the 15 need for minimizing distortion in dimensions to acceptable tolerances. One of the practices widely utilized in molding such housings is to maintain wall thicknesses throughout the connector relatively constant. By that is meant that wall thicknesses varying much more than 50 20 percent through any section of the connector between mold surfaces, between an outer mold shell and core pins, may experience not only distortion, but tolerance variations and a visual appearance, which is unacceptable. Longer mold cycles may remedy some of these shortcomings, though 25 not all, and will lead to a substantial increase in cost of housings. With respect to one widely used type of thermoplastic housing, the interior bore of the housing has been made to include a contact receiving sleeve that forms a bearing 30 segment to support the contact radially within the housing, the sleeve thickness being made along most of its length approximately equal to other wall thicknesses of the housing. This interior sleeve typically includes an inwardly directly beveled or tapered surface that serves 35 to guide contacts during insertion of such contacts within 15366 NZ ^4 837 1 - 2 - a housing. With respect to male contacts having a rounded forward end, such sleeve works generally adequately without stubbing, but with female contacts that have a blunt or squared end, problems have arisen due to stubbing 5 with the female contact catching on the end of the sleeve if the sleeve is not adequately concentric or if the contact is not properly lined up. This sort of problem is aggravated by a lack of concentricity of the sleeve caused by high speed mold cycles or variations in plastic 10 material. At one time the contact bearing segment was made solidly, but problems were experienced with a lack of roundness of the bore through the segment causing, on occasion, contact backout due to the lances of the contact becoming aligned with an out of round bore segment. 15 Another problem associated with housings of the prior art relates to the breakage or elongation of the sleeve due to muscle pulls. After the housing has been molded, the core pin can stick to the material of the sleeve, thereby causing the sleeve to be damaged as the core pin 20 is removed. This is a frequent occurrence as the sleeve is not supported over its entire length. If the sleeve is torn or elongated, the contacts cannot be properly seated and locked within the housing. Accordingly, it is an object of the present invention 25 to provide an improved electrical connector housing that facilitates an easy and reliable insertion of electrical contacts within the housing. It is a further object to provide a molded plastic housing having a beveled entry to facilitate guiding contacts during insertion with minimum 3 0 distortion caused by unduly thick sections of plastic material surrounding the contact bearing segment. It is still a further object to provide a thermoplastic housing of molded material having a configuration facilitating high speed molding with minimum distortion and minimal 3 5 muscle pulls. 15366 NZ - 3 - 2<837 1 It is a final object to provide a contact housing that includes interior beveling or tapering to facilitate contact entry and at the same time, a housing geometry facilitating high speed molding with minimum plastic 5 distortion. The present invention features an electrical connector housing, typically having a plurality of cavities or contact receiving bores extending therethrough. In accordance with the invention, each bore 10 is made to include an entry segment of a given diameter leading to a contact bearing or support segment of a lesser diameter and a forward segment of a larger diameter than the diameter of the bearing segment that overlies a contact end. There is provided a step extending radially 15 between the contact bearing segment and the forward segment defining a surface receiving the end of one or more lances that preclude contact backout. There is provided a beveled or tapered surface or surfaces leading from the bore entry segment to the contact support segment 20 to receive the end of an inserted contact, particularly the blunt end of a female contact and guide such contact to enter the bore support segment and pass therethrough into the front segment with the contact lance or lances engaging the step to hold the contact within the housing. 25 In accordance with the invention in a preferred embodiment, the guiding surfaces are comprised of a series of beveled surfaces leading from the diameter of the entry segment to the diameter of the bearing segment with a series of recesses extending between discrete surfaces 30 disposed around the periphery of the bores, such recesses extending at least substantially along the length of the bore support segment to maintain a thickness of material in that region that is .approximately constant with respect to the thickness of the portions of the housing. The 35 recesses in the present invention are tapered from the 15366 NZ 2* 8 37 1 - 4 - entry segment toward the forward segment to facilitate tapered core pins and an easy withdrawal with minimum distortion of the plastic. In this way, the housing is given the tapered interior bore facilitating contact 5 insertion, and at the same time, minimizes bore distortion which could allow contact backout due to a lance aligning itself with the distorted portion of the bore and as well precluding sink marks in the exterior surface of the housing and/or other distortions that are objectionable. 10 The invention also contemplates that the recesses may be formed from the opposite end of that just expressed, namely, leading from the forward end toward the entry end to maintain the wall thickness and still allow a tapered surface leading from the entry end toward the bore support 15 segment. The invention will now be described by way of example with reference to the accompanying drawings in which: Figure 1 is a perspective view of a connector housing, partially sectioned and showing a contact prior 2 0 to full insertion within such housing. Figure 2 is a end view from the entry end of the housing shown in Figure 1. Figure 3 is a section taken along lines 3-3 of the housing shown in Figure 2. 25 Figure 4 is a view of the housing from the entry end, partially sectioned of Figure 1. Figure 5 is an end view of the housing in accordance with the prior art. Figure 6 is a side and sectional view of a portion of 3 0 the housing taken along lines 6-6 of Figure 5. Referring now to Figure 1, a connector 10 may be seen to comprise a contact 12 and a housing 18 , made from a material such as nylon. The housing 18 receives and supports contact 12 for intermating with a contact in a 35 further connector, not shown, along an axis A. The 15366 NZ 24 8 37 1 - 5 - contact 12, an end portion only being shown, is typically interconnected to a wire that is part of a harness utilized to interconnect electrical or electronic devices. The contact 12 is typically stamped and formed of a spring 5 grade conductive material, such as brass or phosphor bronze, suitably plated, with an alloy of tin or, in certain instances, precious metal. The contact 12 includes at least one lance 14 struck from the outside thereof that is utilized to latch the contact within 10 housing 18. Contacts such as 12 may be either male or female contacts in accordance with widespread usage. Male contacts typically have a rounded end that facilitate insertion into housing such as 18, but female contacts have a blunt or sharp edge leading to an interior 15 receptacle portion into which is plugged a male contact in use. Figures 5 and 6 show prior art examples of connectors of the type described. Figure 5 shows an entry end of a connector housing 18' having an entry bore 36', an 20 interior sleeve 31 having a bevel 34' leading to a contact support bore segment 28'. Figure 6 shows this in relationship to a forward bore 25' and a step 26' extending between the forward portion 25' and the contact bearing portion 28'. As can be seen, the sleeve 31 25 extends out into the entry bore segment 36' and as can be seen, a contact 12' being inserted within bore 36' if not properly aligned, may stub on the end of the sleeve 31, despite the beveled surface 34'. The sleeve 31 replaced a prior art solid section in the region of the support 3 0 segment 28' in order to reduce the distortion of the bore 28' and further distortion in the exterior surface of the housing. The resulting structure, however, has been realized to cause occasional but undesirable stubbing during contact insertion as is depicted in Figure 6. 35 The present invention represents an improvement over 15366 NZ - 6 - 2 4 8 J 7 7 this prior art through the provision of details to be described. Referring back to Figure 1, the housing 18 may be seen to include a number of features, such as the hinge shown as 19, allowing latching members 17 of the housing 5 to flex for latching purposes or for engagement purposes. There is a central housing portion 20 that contains a pair of apertures or bores 22 that extend therethrough along an axis of insertion of the contact and of the mating of the connector half and housing 18 with another connector half, 10 not shown. The housing 20 includes forwardly projecting sleeves 24 that have forward bores 25 leading to a step 26 and a contact support segment in bore 28 of a reduced diameter and onto an interior bore 3 6 that represents an entry segment of the bore 22. The bore 36 is of a 15 substantially larger diameter than bore 28. As can be seen in Figures 1 and 2, the bore 28 has a transition to bore 3 6 in the form of a surface 34 that is beveled or tapered from bore 28 to bore 3 6 in the manner shown in Figure 3. These surfaces 34 are interruped by a series of 20 recesses 30 that lead interiorly along the segment of bore 28. The recesses 30 are separated by segments 32 as shown in Figures 2 and 3 that extend along the length of the segment defined by bore 28 to an end surface 29 as shown in Figures 1 and 4. As can be appreciated from Figures 1 25 and 2, the recesses 30 are tapered, narrowing along the length of segment bore 28. Figure 3 shows the advantage of the configuration to include the tapered or beveled surface 34, noting the engagement with end 16 of contact 12 on surface 34 tends to guide the contact insertion into 30 the support bore 28 and into the housing to a point where the lance 14 of the contact will snap outward to engage the step 26 and lock the contact within bore 22 and to housing 18. It has been found that providing reliefs and segments 35 with plastic arranged as described and shown in Figures 1- 15366 NZ ^4 a 37 - 7 - 4 minimizes distortion of the bore 28, a sinking of material in the exterior of the housing and as well provides a tapered surface leading from bore 3 6 to bore 28 and easing insertion of contacts thereinto. The reliefs 5 and segments also prevent muscle pulls from destroying the integrity of the bore. As the segments are supported over their entire length, the removal of the core pin after molding does not tear or elongate the segments. Consequently, the contacts 12 will be properly seated in 10 the housing. The invention utilized some eight segments 32 in one embodiment, and the beveled surfaces 34 were tapered relative to the insertion axis a shown in Figure 3. The invention fully contemplates alternative embodiments as 15 for example where the recesses 3 0 are made to lead from the bore segment 25, originating at step 2 6 and leading rearwardly, tapered as previously to accommodate tapered core pins. Alternatively, the recesses 3 0 could be alternated with every other recess leading from the bore 2 0 25 and the opposite recess leading from bore 36. In both the foregoing embodiments, the tapered surface 34 would be maintained, the point being that balancing wall thickness minimizes bore distortion and plastic surface sinking. The invention contemplates that 25 fewer recesses 30 may be employed and fewer segments 32, as long as there is a beveled guide end leading from the bore 3 6 to bore 28 guiding the contact within the housing, and sufficient balance of wall thickness maintained to prevent distortion. 3 0 Having now described the invention in terms intended to enable a preferred practice thereof, claims are set forth which define what is deemed inventive. 15366 NZ 24 8 37 1 - 8 - ADVANTAGES OF THE INVENTION An advantage of the invention is an electrical connector housing wherein the contact-receiving bore (22) has a series of beveled surfaces (34) extending between an 5 entry segment (36) of the contact-receiving bore and a support segment (28) of the contact-receiving bore. Another advantage of the invention is a series of recesses (30) within the support segment (28) that maintain a relatively constant wall thickness of the 10 support segment. </div>

Claims

<div class="application article clearfix printTableText" id="claims"> WHAT WE CLAIM IS:

1. An electrical connector housii

-9-

type molded through the use of core pins, the housing having at least one bore adapted to receive an electrical contact inserted therein, the bore having a first entry segment of a specified diameter into which the contact is initially inserted and a support segment of a lesser diameter adapted to support the contact in said housing, the support segment having an interior sleeve having a continuous, inwardly directed wall, characterised in that a bevelled surface leads from said entry segment to said support segment to define a taper to guide the insertion of the contact into the bore and minimise stubbing during insertion exteriorly of the sleeve there being recesses which extend through the housing parallel with the interior sleeve, the recesses being open on one end and being closed along the length of the sleeve and closed at another end, and a series of rib segments, separating the recesses, the ribs co-operating with the interior sleeve to maintain the material thickness of the interior sleeve in the region of said support segment approximately constant to preclude bore distortion and surface sinking of said housing.

2. The electrical connector housing of claim 1, characterised in that said bevelled surface is comprised of at least two distinct bevelled surfaces disposed oppositely relative to the entry segment of the bore extending around the periphery.

3. The electrical connector housing of claim 1, characterised in that said bevelled surface is comprised of segments disposed around the periphery of the entry segment bore, and each recesses being disposed along an axis parallel to an axis of said bore.

4. The electrical connector housing of claim 3, characterised in that said recesses open into the entry segment of the said bore.

5. The electrical connector housing of claim 1, characterised in that said bore includes a forward segment to receive a contact end with the forward segment joining the support segment and with at least some of said recesses opening from the forward segment.

of the said axis to facilitate core pin withdrawal with minimum housing distortion.

7. An electrical connector housing formed of a plastics material adapted to receive and position at least one electrical contact for intermating with a further electrical contact in a further housing along a mating axis wherein the said one contact includes a forward contact portion and at least one retention lance at the base of said portion extending radially outward, said housing having a bore extending therethrough along said axis with an internal step adapted to be engaged by said lance to latch the contact in said housing, said step leading to a reduced diameter bore of a length defining a support portion for a segment of the contact radially relative to said axis, the support portion having an interior sleeve with a continuous inwardly directed wall, characterised in that said support portion has a series of recesses extending therealong disposed exteriorly of the interior sleeve in the housing periphery around said support portion, the recesses being open to one end and being closed along the length of the interior sleeve and also being closed on another end, the recesses being directed to maintain an approximate wall thickness of the material of said housing in the region of said support portion to provide a constant bore diameter and reduce sinking in said housing, and a further entry segment with a bevelled surface leading to said support portion to facilitate entry of said contact into said housing.

8. The electrical connector housing of claim 7, characterised in that said housing is comprised of resilient housing material to include a resilient latch formed integrally therewith.

9. The electrical connector housing of claim 7, characterised in that said recesses are spaced to form a spoke-like configuration in cross-section through said support portion.

10. An electrical connector housing substantially as herein described with reference to the accompanying drawings, except Figures 5

and 6.

DATED THISKDAY OF Kf«r/ 19^

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'PUCANTS

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